Machine for folding carton blanks



' April 22, 1969 w, GE|5LER ET AL 3,439,589

MACHINE EQR FOLDING CARTON BLANKS Sheet Filed May 6, 1966 FlG 2 INVENTORS K WER LA SL BC. E GR mmy w UM ,M m v N April 22, 1969 w GEISLER T MACHINE FOR FOLDING CARTON BLANKS Filed May 6, 1966 INVENTORS WILLIAM GEISLER ATTORNEYQ 5 v @E 1 80 mm 8m Sheet NORMAN R. CEARK April 22, 1969 w, GE|$LER ET AL 3,439,589

MACHINE FOR FOLDING CARTON BLANKS Filed May 6, 1966 I a Q U Q INVENTORS -W|LLIAM GEISLER BY NORMAN R. CLARK ATTORNEYS FIG 8A April 22, 1969 w. GEISLER ETAL MACHINE FOR FOLDING CARTON BLANKS Filed May 6, 1966 Sheet 4 of 4 INVENTORS WILLIAM GEISLER BY NORMAN R. CLARK ATTORNEYS r S OI United States Patent 3,439,589 MACHINE FOR FOLDING CARTON BLANKS William Geisler and Norman R. Clark, San Francisco,

Calif., assignors to Fibreboard Corporation, a corporation of Delaware Filed May 6, 1966, Ser. No. 548,123 Int. Cl. B31b 1/36, 1/40, 1/72 U.S. Cl. 93-52 7 Claims ABSTRACT OF THE DISCLOSURE tube.

This invention relates to a machine and method for folding carton blanks and more particularly relates to a machine and method for folding panels of a flattened sheet of paperboard or like material and securing edges thereof together to form a tube. The tube is preferably double-walled and comprises a constant thickness throughout. The tube is adapted to be erected into a cylinder or carton having a polygonal cross-section.

Cartons adapted to contain ice cream or like commodities must exhibit high structural integrity and resistance to contamination and leakage. Difliculties have been encountered when cylindrically shaped cartons are utilized for such purpose due to the further requirement of economy, including the high production rates required therefor. Such cartons may be shipped to a packaging plant in a flattened condition, formed into the desired shape, filled and closed at both ends thereof. Alternatively, the cartons may be fully formed and then shipped to such plant. It is desirable to construct and arrange such a flattened, partially formed carton or tube so that a minimum amount of Work is needed to form a structurally sound, moisture resistant and leakproof carton in a continuous manner.

The machine and method of this invention essentially provide for the continuous, economical and expeditious, folding of a single sheet of material or carton blank to form a flattened tube. The preferred blank is multipaneled and adapted to be formed into an integrated tube having a double-walled thickness throughout. An adhesive moisture barrier constituent or laminant may be arranged between the walls to strengthen the formed carton and also to resist leakage, including vapor transmission, and contamination of the cartons contents. A laminant may also be formed on the inner and outer portions of the carton if so desired.

The latter tube originally comprises a multi-paneled blank which is first folded in the direction in which it is conveyed to superimpose first and second panels thereof. End portions of the folded sheet are then folded towards each other, transversely to the first fold and secured together to form the tube. The end portions of the blank are preferably arranged so that the tube comprises a double paneled wall having a constant thickness throughout. The blank may originally comprise a laminant formed on one or both sides thereof to thus provide a barrier coating on the inner, intermediate and/or outer surfaces of the formed carton. Further novel features of this invention will be made apparent from the specific descriptions set forth hereinafter.

An object of this invention is to provide a machine and 3,439,589 Patented Apr. 22, 1969 method for continuously, economically and expeditiously folding a sheet of material to form a tube.

Another object of this invention is to provide a machine and method for folding a carton blank in the direction in which it is conveyed, folding end portions of the blank into superimposed relationship and securing the end portiorlis together to form a tube having a double paneled wa 1.

Another object of this invention is to provide a machine and method for coating at least one side of a multipaneled blank with a laminant and folding the blank to form a tube having such laminant coated on inner and outer surfaces thereof.

Another object of this invention is to provide a mechanism and method steps for precisely folding a sheet of material about a score line arranged perpendicular to the direction in which it is conveyed.

Another object of this invention is to provide a mechanism and method steps for folding end portions of a blank in a transverse direction relative to a line of flight thereof to precisely fold such portions into superimposed and overlapped relationship regardless of blank misalignment in such transverse direction.

Further objects of this invention will become apparent from the following description and accompanying drawings wherein:

FIG. 1 illustrates a preferred carton comprising a tubular blank made pursuant to the machine and method of this invention;

FIG. 2 is a cross-sectional view taken in the direction of arrows 22 in FIG. 1;

FIG. 3 is a view similar to FIG. 2 illustrating the carton of FIG. 1 prior to the application of end closures thereto;

FIG. 4 schematically illustrates the machine and method of this invention;

FIG. 5 is a schematic View sequentially illustrating a carton blank as it would appear at corresponding stations A through H in FIG. 4;

FIG. 6 is a fragmentary view illustrating a tube formed by the machine and method of FIGS. 4 and 5;

FIG. 7 illustrates an alternative carton blank which may be formed into a tube by the apparatus and method illustrated in FIGS. 4 and 5;

FIGS. 8A-8D are side elevational views with parts broken away disclosing a mechanism for performing a folding operation at station C in FIGS. 4 and 5;

FIGS. 9A-9D are top plan views corresponding to FIGS. 8A-8D, respectively;

FIG. 10 is a cross-sectional view illustrating specific constructions and arrangements of scoring rolls located at station E in FIG. 4;

FIG. 11 is a top plan view of sequential steps occurring during a folding operation at station G in FIG. 4;

FIG. 12. is a side elevational view coordinated with the view disclosed in FIG. 11;

FIG. 13 is a view taken in the direction of arrows 1313 in FIG. 11;

FIG. 14 is a view taken in the direction of arrows 14-- 14 in FIG. 11; and

FIG. 15 is a view taken in the direction of arrows 15-15 in FIG. 11.

CARTON DESCRIPTION The carton disclosed in FIGS. 1 and -2 comprises a removable cover 17 and a fixed end closure 18 secured to a tubular blank or body portion 19. The blank preferably comprises an inner or first panel 19a and an outer or second panel 19b adhered together to form a moisture barrier therebetween. The tubular blank, partially illustrated in its flattened condition in FIG. 6, may be formed into a cylindrical shape by a suitable mandrel or like device. Once the flattened blank is opened to assume the cylindrical configuration disclosed in FIG. 3, cup-shaped end closure 18 may be beaded thereto in the manner illustrated in FIG. 2.

A suitable bead may be formed on the top edge of body portion 19 to receive cover 17 or a conventional capseat may be formed below such edge for receiving a plug-type lid. The cover may comprise a paperboard, plastic or other suitable material. A see-through plastic window 17a may be arranged in the cover if so desired. A laminant could be applied to one or more surfaces of the carton during its formation for purposes hereinafter explained. The term laminant or coating will hereinafter mean polyethylene, aluminum foil, grease-proof paper, wax coating or any other suitable constituent having similar characteristics.

It should be noted that panels 19a and 19b (FIG. 5 at station A) are offset in the direction of score line S to define an offset end portion on each panel. Thus, when the offset end portions are secured together the double walled tube comprises a constant wall thickness throughout. FIG. 7 discloses a modified blank wherein the edges of panels 19a and 19b are angled in the manner illustrated to provide a spiraled seam on the completed body portion of the carton.

MACHINE DESCRIPTION FIGS. 4 and 5 schematically illustrate the preferred machine and method steps utilized to form multi-paneled blank 19 into the tube illustrated in FIG. 6. Starting at station A and moving from left to right in these figures, conveyors are suitably arranged in a conventional manner to have lugs 20a thereof engage flattened sheet or blank 19 to continuously convey it in a first direction along a line of flight through the machine. Portions of the conveyor and other elements are omitted from these figures for clarification purposes.

The first laminant or coating application means, preferably in the form of a conventional roll 21 mounted to rotate with shaft 21a, may be arranged at station B to apply a coating, such as a standard glue, to selected portions of blank 19. A conventional glue pattern 21b is suitably etched on the roll and arranged to cooperate with a conventional glue feed means (not shown) to transfer and evenly distribute the desired amount of glue thereon. For example, such glue feed means may comprise a suitable dam type reservoir (not shown), arranged adjacent to the roll to transfer the glue to pattern 21b. Other well known means may be employed to evenly distribute the glue or other laminant onto the pattern. Also, if a polyethylene or like coated blank is utilized, a heating means may be substituted in lieu of glue pattern 21b to melt such coating on panel 191; to permit the panels to be secured together in the manner hereinafter explained.

A first folding means is arranged at station C and comprises folding mechanisms or first and second means 22 and 23 which cooperate with resilient finger members or third means 24 and to fold panels 19a and 19b of the blank about score line S and into superimposed relationship (FIGS. 8A- 8D and 9A-9D). Mechanism 22 comprises a rotatable shaft 22a having members 2212 and 220 adjustably mounted thereon for purposes hereinafter explained. Wires or like members 22d are preferably attached to extremities of members 22b and 220 in the manner shown in FIG. 9A to aid in precisely breaking score line S FIGS. 8A and 9A more clearly disclose the manner in which members 22b and 22c are adjustably mounted on shaft 22a. Collar members 22c and 22 are keyed or otherwise suitably secured to shaft 22a and have arc-uately shaped apertures formed therein arranged in juxtaposed relationship to corresponding ones formed in members 2212 and 220, respectively. Bolt means 22g and 2211 are suitably arranged to extend through these apertures in the manner illustrated to secure each member 22b and 220 to its adjacent collar member. Thus, it can be seen that a loosening of bolt means 22g and 22h will permit members 221) and 220 to be rotated relative to their adjacent collar members and shaft 22a to correctly position the members thereon for a particular folding application.

Mechanism 23 is substantially identical to mechanism 22 and has like subscript letters (accompanying numeral 23) to depict corresponding structures. It should be noted that adjustment of mechanism 22 relative to mechanism 23 permits wire members 22d and 23d to be rotated adjacent to each other to effect a precise fold in a manner hereinafter explained. Resilient finger members 24 and 25 are suitably secured to stationary columns 24a and 25a, respectively, and positioned thereon to cooperate with mechanisms 22 and 23 during the folding step at station C (FIG. 4).

As illustrated, each of the finger members comprises a resilient material, such as spring steel, which will function to engage a leading edge of panel 19a of blank 19 and fold it in a second direction, opposite to the above-mentioned first direction, of blank movement (FIGS. 8A- SD). The dimensions of the finger members as well as the physical makeup thereof may be controlled to afford the degree of resiliency required for a particular folding operation. Conveyor 20 is further arranged in FIG. 4 to move the folded blank under hold down bars 26, 27 and 28. The leading edge of each of the hold down bars preferably comprises a curved portion to facilitate reception of the blank thereunder.

Moving now to station D in FIG. 4, juxtaposed pressure rollers 29 and 30, mounted on rotatable shafts 29a and 30a, respectively, are arranged to compress the folded panels of the blank together to set the glue or other suitable adhesive therebetween. The compressed blank is then conveyed towards station E, comprising scoring means preferably in the form of rolls 31 and 32 mounted on rotatable shafts 31a and 32a, respectively. FIG. 10 is a cross-sectional view disclosing the preferred construction of the scoring rolls. It should be noted that roll 31, for example, preferably comprises a rubber or like resilient coating 31b for preventing damage to the carton blank by the rolls. Ring members 310 and 31d are secured to shaft 31a and comprise scoring flanges or ridges 31c and 31 formed on the respective peripheries thereof.

Roller 32 is substantially identical to roller 31 and has like subscript letters (accompanying numeral 32) to depict corresponding structures. The primary difference between the rolls is that roll 32 comprises grooves 32e and 32 arranged to cooperate with flanges 31e and 31 of roll 31 to form scores S and S arranged parallel to the line of blank flight (FIG. 5, station E). The rolls may be arranged to form the scores in the positions illustrated or in any other desirable position. For example, the rolls may be positioned so that one score is formed on one panel only (adjacent to the edge of the other panel) and the second score formed on the two superimposed panels (S and S in FIG. 5, station E).

Moving to station F, second glue application means, preferably in the form of conventional rolls 33 and 34 mounted on rotatable shafts 33a and 340, respectively, have etched glue patterns formed thereon similar to glue pattern 21b formed on roll 21. Rolls 33 and 34 are arranged to apply a glue pattern to opposite end portions of the blank as illustrated at stations F and G in FIG. 5. Conventional glue feeds means (not shown) are arranged to evenly distribute the desired amount of glue or other suitable adhesive onto the peripheries of rolls 33 and 34. It should be understood that in certain carton applications only one such glue roll need be utilized. Also, a suitable heating means may be substituted in lieu of rolls 33 and 34 if a polyethylene or like coated blank is utilized to melt selected portions of the coating prior to when the end portions of the blank are secured together.

The scored and glued blank is then moved through station G comprising endless belts or means 35 and 36, partially disclosed in FIGS. 4 and 5. The belt means are suitably twisted and trained to cooperate with stationary hold down bar means 37 and 38, arranged to receive and hold down a mid-portion of the blank thereunder, to fold end portions of the blank transversely relative to the line of flight of the blank and into superimposed relationship. As more clearly illustrated in FIG. 11 (sub-stations G-l through G-6), belt 36 is arranged to cooperate with hold down bar 38 to fold the lower end portion of the blank before belt 35 cooperates with hold down bar 37 to fold the upper end portion of the blank. It should be understood that the belts and hold down bars may be suitably repositioned to accommodate differently positioned scores, such as scores S and S However, it can be seen that the above-described arrangements may be constructed to allow for blank misalignment transversely to the line of blank flight, i.e., the transverse length of the blanks mid-portion will substantially equal the additive length of the end portions thereof to thus compensate for such misalignment.

The folded blank is then transferred by conveyor 20 (not shown) onto an endless belt-type conveyor 39 at station H. Compression rolls or means 40 then function to secure the end portions of the blank together to form a tube. The tube, partially disclosed in FIG. 6, is then adapted to be formed into cylindrical shaped body portion 19 0f the carton illustrated in FIG. 1. As abovementioned, other shapes could, of course, be formed.

Additional hold down bars 41 and 42 (FIG. 11) may be employed to assure proper guidance of the folded blank to conveyor 39. Compression rolls 43 and 44 may be utilized to compress the formed folds if so desired. In certain applications it is desirable to initially coat one or both sides of the blank with a laminant by roller means 45, arranged adjacent to the first folding means in FIG. 4. Also, a suitably arranged spray, brush or felt pad means 46 may be arranged adjacent to scoring rolls 31 and 32 to apply a laminant or barrier constituent to one or more edges of the blank. Such a coating will aid in effecting a sealed inner seam of formed carton.

METHOD OF OPERATION Although the above-described machine may be utilized to perform the hereinafter described method, it should be understood that one skilled in the art could readily follow the teachings herein and utilize other suitable machinery therefor. In general, the method of this invention comprises the steps of moving the single sheet or blank 19 rightwardly along a line of flight in FIG. 5, folding the first and second panels of the blank in the direction of such line of flight and then folding end portions of the blank transversely to such line of flight and into superimposed relationship to form a tube. The panels are preferably offset, as shown at station A in FIG. 5, to permit the completed tube to assume a constant, double-walled thickness throughout (FIG. 6). The tube, when formed into a carton illustrated in FIGS. 1 and 5, will thus exhibit high structural integrity and resistance to leakage and contamination.

The more specific steps included in the preferred method will now be explained. Such steps comprise moving blank 19 in a first direction along a line-of flight towards station A and coating the bottom side of the blank with the desired laminant by rollers means 45. The next step is one of applying a barrier coating or adhesive to one of the blanks panels at station B. Although the adhesive is preferably applied to second panel 19b, it should be understood that the adhesive could be applied to the first panel. Also, as above explained the blank may comprise a polyethylene or like coating. In such an application, roller 21 would be arranged for heating and melting the polyethylene applied to panel 19b.

At folding station C (FIGS. 4 and 8A-D), mechanism 23 is arranged to rotate clockwise for applying a folding force via wire 23d to first panel 19a of the blank. Mechanism 22 is arranged to rotate counter-clockwise for applying a back-up force to second panel 1% via wire 22d, adjacent score line S Finger members 24 and 25 are arranged for catching and retarding movement of the leading edge of first panel 19a as illustrated in FIG. 8C. Mechanisms 22 and 23 and resilient finger members 24 and 25 are thus arranged for progressively and precisely folding first panel 19:: in a second direction, opposite to the first direction of carton flight, to fold the panels into superimposed relationship in the manner illustrated in FIGS. 8A-8D.

The mechanisms initiate the break at score line S whereafter continued movement of the blank in its linear line of flight permits the resilient finger members to engage the leading edge of first panel 19a. The finger members then move counter-clockwise about the pivot points whereat they are affixed to stationary columns 24a and 25a. The finger members are further arranged for releasing the blank after the fold has been substantially completed. Hold down bars 26, 27 and 28 are arranged for trapping the blank thereunder to complete the fold. The panels are held in their superimposed position during travel to station D.

Compression rollers 29 and 30 are arranged at this station for applying a sealing pressure to the two superimposed panels to form a moisture barrier therebetween. Rollers 31 and 32 are arranged at station E for scoring the folded blank to define opposite end portions thereon by score lines S and S arranged parallel to the direction of carton flight. Rolls 33 and 34 are arranged adjacent to the scoring rolls for appplying glue or other suitable adhesives to the formed end portions. If the blank comprises a polyethylene or like coating, rolls 33 and 34 would constitute heating means for melting such coating on portions of the panels adjacent thereto. Means 46 may be arranged for applying a barrier constituent to at least one of the edges of the end portions of the blank for purposes hereinbefore explained.

Hold down bars 37 and 38 are arranged for receiving the mid-portion of the blank thereunder and holding it down on a platen (not shown) adjacent score lines S and S As more clearly disclosed in FIGS. 11 and 12, belt 36 is arranged to cooperate with bar 38 for first folding the lower end portion of the blank about score line S transversely to the line of flight of the blank, at stations G1 through G-3. Belt 35 is arranged to cooperate with bar 37 for thereafter folding the opposite end portion of the blank towards the other end portion during carton flight from station G2 through station G4. The hold down bars and belts are further arranged for transferring the folded carton between endless belt 39 and rollers 40. The latter structures are arranged for compressing and adhering the superimposed end portions of the blank together to form the flattened tube disclosed in FIG. 6. Rollers 43 and 44 or their equivalent may be utilized to compress the folds of the carton if so desired.

Since the blank has been preferably arranged so that first and second panels 19a and 1% are offset in the direction of score line S to define offset end portions on each panel, the double-walled tube assumes a constant wall thickness throughout. The tubular blank is then adapted to be shipped in a flattened condition whereafter such blank may be formed into the type of carton or container illustrated in FIGS. 1 and 2. It should be understood that conventional drive mechanisms may be suitably arranged by one skilled in the art to impart the desired movements to the above-described elements. Since such drive mechanisms per se do not comprise novel aspects of this invention, further explanation thereof will not be made.

We claim:

1. A machine for folding a flattened blank, said blank comprising first and second panels joined by an intermediate score line, said machine comprising conveyor means for moving said blank along a line of flight, first folding means for folding said first and second panels into superimposed relationship about said score line along said line of flight, second folding means for folding opposite end portions of said blank transversely relative to said line of flight and into superimposed relationship, said second folding means comprising hold down bar means for receiving a mid-portion of said blank thereunder and means arranged to cooperate with said hold down bar means for folding the end portions of said blank into superimposed relationship, means arranged adjacent to said second folding means for applying a barrier constituent to at least one of the edges of the end portions of said blank to effect a sealed seam when said end portions are secured together, scoring means arranged between said first and second folding means for forming two score lines on said blank to define the end portions thereof, said scoring means arranged to form said last-mentioned score lines on said blank in parallel relationship to said line of flight to define a mid-portion on the blank between said score lines having a transverse length relative to said line of fiight substantially equaling the additive transverse lengths of said end portions, application means for applying an adhesive to at least one of the end portions of said blank and means for securing the end portions of said blank together to form a double-walled tube having a constant wall thickness throughout.

2. The invention of claim 1 further comprising means arranged adjacent to said first folding means for coating at least one side of said blank with a laminant.

3. The invention of claim 1 wherein said first folding means comprises a first means for applying pressure to a bottom portion of said first panel, second means for applying pressure adjacent said score line to a top portion of said second panel and third means for engaging a leading edge of said first panel and cooperating with said first and second means to fold said panels into superimposed relationship.

4. The invention of claim 3 wherein said third means comprises a resilient finger member.

5. The invention of claim 3 wherein said first and second means are rotatably and adjustably mounted adjacent to said conveyor means.

6. The invention of claim 1 further comprising application means arranged adjacent to said first folding means for applying a barrier coating between said first and second panels prior to when said panels are folded into superimposed relationship.

7. The invention of claim 1 wherein said means cooperating with said hold down bar means comprises first and second belt means, said first belt means arranged to fold one end portion of said blank after said second belt means has folded the other end portion thereof.

References Cited UNITED STATES PATENTS 996,785 7/1911 Motz 93-94 X 1,281,356 10/1918 Harbeok 93-94X 2,117,460 5/1938 Staude 93-52 2,125,147 7/1938 Bergstein 93-56 2,296,896 9/1942 Bergstein 93-52X 2,883,917 4/1959 La Bombard 93-49 2,982,189 5/1961 Shields 93-49 3,029,175 4/ 1962 Stenqvist.

3,055,152 9/1962 Williams 93-49 3,079,144 2/1963 Frei 93-84 3,176,596 4/1965 Triolo 93-52 X 3,242,829 3/ 1966 White 93-94 3,272,094 9/ 1966 Carpenter 93-94 X 3,303,760 2/1967 Tobias 93-36 3,322,045 5/1967 Tanona 93-36 WAYNE A. MORSE, JR., Primary Examiner.

US. Cl. X.R. 

